Method for forming or repairing parts having overhangs, and related turbomachine parts

Abstract

To form or repair a part with an overhung section, and to provide a related turbomachine blade.SOLUTION: When forming or repairing a part with an overhung section, a portion is removed and a section is added to the portion. The section includes the overhung section. The adding includes sequentially layering at least a plurality of material layers onto the part, the at least plurality of material layers approximating dimensions of the section including the overhung section. The sequential layering may include, for example, laser welding, and may be carried out in a number of ways that create varied layers within the overhung section. The method may include machining the at least one plurality of material layers to form the section including the overhung section.SELECTED DRAWING: Figure 14

Description

Technical Field

[0001] The present disclosure generally relates to the manufacture and repair of components, and more particularly to methods for forming or repairing turbomachine components such as turbomachine blades having overhang portions.

Background Art

[0002] Industrial components may have portions that overhang from other portions of the component. The overhung portions may need to be added during formation or repaired after the period of use. One exemplary application includes flared tips of turbomachine blades such as those available from General Electric Company (Schenectady, New York). The flared tip turbomachine blade includes an airfoil having a pressure side and a suction side joined along a leading edge and a trailing edge. The flared tip is joined to the radially outer end of the airfoil and can extend circumferentially beyond the pressure side and / or suction side of the airfoil, i.e., with respect to the axis of the turbomachine. Conventional non-flared turbomachine blades, for example, need to stack materials two-dimensionally in the vertical or radial direction using Additive manufacturing (casting or additive manufacture). In the manufacture of flared tip turbobladed, materials are added in both the circumferential and radial directions. Since the repair of flared tip turbomachine blades is currently impossible, they are replaced. Other turbomachine high temperature gas path components and other industrial components also have overhang portions, and the situation is similar.

Summary of the Invention

[0003] One aspect of the present disclosure provides a turbomachinery component. The turbomachinery component comprises a body having a first side surface, a second side surface, and a longitudinal axis, and an overhang portion extending overhanging from at least one of the first side surface and the second side surface of the body. At least a portion of the overhang portion comprises a plurality of material layers, each material layer extending at an acute angle with respect to the longitudinal axis of the body.

[0004] Another aspect of the present disclosure relates to a method for adding a section to a part, the section including an overhang, and the addition involves sequentially laminating a plurality of material layers on the surface of the part, the plurality of material layers approximating the dimensions of the section including the overhang. The method includes machining the plurality of material layers to form the section including the overhang.

[0005] One aspect of this disclosure relates to a method for forming an overhang on a part, the method comprising forming a surface on the part, the surface being at an angle that is neither perpendicular nor parallel to the target outer planar surface of the overhang. The method comprises sequentially laminating a plurality of material layers on the part, the plurality of material layers approximating the dimensions of the overhang. The method comprises machining the plurality of material layers to form the overhang and the target outer planar surface, the target outer planar surface being at an angle to the plurality of material layers.

[0006] One aspect of the present disclosure provides a turbomachinery component. The turbomachinery component comprises a body having a first side surface, a second side surface, and a longitudinal axis, and an overhang portion extending overhanging from at least one of the first side surface and the second side surface of the body. At least a portion of the overhang portion comprises a plurality of material layers, each material layer extending perpendicular to the longitudinal axis of the body.

[0007] Another aspect of the present disclosure provides a turbomachinery component. The turbomachinery component comprises a body having a first side and a second side, and an overhang portion extending overhanging from at least one of the first side and the second side of the body. At least a portion of the overhang portion includes a first plurality of material layers extending in a first direction, and a second plurality of material layers extending in a second direction in a non-planar direction with respect to the first direction of the first plurality of material layers.

[0008] One aspect of the present disclosure relates to a method, which includes adding a section to a part. The section includes an overhang, and the addition includes sequentially laminating a first plurality of material layers onto a part extending in a first direction, and sequentially laminating a second plurality of material layers onto a part extending in a second direction different from the first direction. The second plurality of material layers meet with the first plurality of material layers, and together the first plurality of material layers and the second plurality of material layers approximate the dimensions of the section including the overhang and are non-planar with respect to each other. The method includes machining the first plurality of material layers and the second plurality of material layers to form the section including the overhang.

[0009] The exemplary embodiments of this disclosure are designed to solve the problems described herein and / or other problems not discussed herein. [Brief explanation of the drawing]

[0010] These and other features of the Disclosure will be more readily apparent from the following detailed description of various aspects of the Disclosure, taken in conjunction with the accompanying drawings illustrating various embodiments of the Disclosure. [Figure 1] This is a schematic diagram illustrating an exemplary industrial application of a gas turbine configuration that includes turbomachinery components having overhangs such as flared tip rails, according to embodiments of the present disclosure. [Figure 2] Figure 1 is a cross-sectional view of the compressor section of the gas turbine. [Figure 3] This is a cross-sectional view of the turbine section of the gas turbine shown in Figure 1. [Figure 4]This is a perspective view of an exemplary turbomachinery component, a turbine rotor blade having a flared tip rail. [Figure 5] This is a cross-sectional view of an exemplary overhang portion of a flared tip rail, including the portion to be removed and the intended removal line. [Figure 6] This is a cross-sectional view of the part after removing the portion shown in Figure 5 and creating a surface for constructing a new overhang. [Figure 7] This is a cross-sectional view showing how multiple material layers are sequentially stacked on the surface of a component. [Figure 8] This is an enlarged cross-sectional view showing how multiple material layers are each composed of a series of weld beads. [Figure 9] This is a schematic plan view showing a series of weld beads of two layers of material extending in different directions. [Figure 10] This is a cross-sectional view showing the process of machining the area shown in Figure 7 to form a new overhang. [Figure 11] This is a cross-sectional view of the overhang portion of the flared end rail shape, including the portion to be removed and the planned removal line. [Figure 12] This is a cross-sectional view of the part after removing the portion shown in Figure 11 and rotating the part to create a surface for constructing a new overhang. [Figure 13A] This is a cross-sectional view showing multiple material layers sequentially laminated onto the surface of the part shown in Figure 12, in a substantially horizontal position. [Figure 13B] This is a cross-sectional view showing how multiple material layers are sequentially stacked on the surface at a different rotation angle than in Figure 13A. [Figure 14] Figure 13A-B is shown as a cross-sectional view illustrating the process of machining the area to form a new overhang. [Figure 15] Figure 6 is a cross-sectional view showing how multiple material layers in a first direction are sequentially laminated onto the first surface of the component. [Figure 16] This is a cross-sectional view of the part after removing the portion shown in Figure 6 and optionally creating two surfaces for constructing a new overhang. [Figure 17] It is a cross-sectional view of a component after rotating the component and laminating a first plurality of material layers. [Figure 18A] It is a cross-sectional view showing a state in which a second plurality of material layers are sequentially laminated in a second direction on a second surface of a component. [Figure 18B] It is a cross-sectional view showing a state in which a second plurality of material layers are sequentially laminated in a second direction on a second surface of a component. [Figure 18C] It is a cross-sectional view of a component after repeating the sequential lamination of a first and a second plurality of material layers on the component during rotation of the component. [Figure 18D] It is a cross-sectional view showing a state in which a plurality of material layers are sequentially laminated on a component at a non-right angle. [Figure 18E] It is a cross-sectional view showing a state in which a plurality of material layers are sequentially laminated on a component at a non-right angle. [Figure 19] It is a cross-sectional view in which a first plurality of material layers are sequentially laminated in a first direction on a first surface of a component to form an extended portion with a step. [Figure 20] It is a cross-sectional view after rotating the component of FIG. 19. [Figure 21] It is a cross-sectional view showing a state in which a plurality of material layers in a second direction are sequentially laminated on a second surface of the component of FIG. 20. [Figure 22] It is shown as a cross-sectional view showing a state in which a portion of FIG. 21 is machined to form a new overhang portion. [Figure 23] It is a cross-sectional view of a pair of overhang portions in an exemplary portion of a double flare tip rail including a portion to be removed and an intended removal line. [Figure 24] It is a cross-sectional view showing an exemplary overhang portion in the form of a double flare tip rail extending inward. [Figure 25] It is a cross-sectional view of an exemplary overhang portion in the form of a flare tip rail in which a part is removed and the part is rotated by a predetermined angle to form an inclined construction surface. [Figure 26] It is a cross-sectional view showing a state in which a plurality of material layers are sequentially laminated on an inclined surface of a component.

[0011] Please note that the drawings in this disclosure are not necessarily to scale. The drawings are intended to depict only typical aspects of this disclosure and should therefore not be considered as limiting the scope of this disclosure. In the drawings, similar numbering represents similar elements between drawings. [Modes for carrying out the invention]

[0012] Aspects and advantages of this application are described below in the following description, or are evident from the description, or can be learned through the practice of this disclosure. Herein, one or more examples of this disclosure will be referred in detail to embodiments shown in the accompanying drawings. In the detailed description, numerical designations will be used to refer to features in the drawings. As will be understood, each example is provided for illustrative purposes of this disclosure and is not limiting to this disclosure. In fact, it will be evident to those skilled in the art that modifications and variations can be made in this disclosure without departing from its scope or spirit. For example, a feature illustrated or described as part of one embodiment may be used in another embodiment to obtain yet another embodiment. This disclosure is intended to cover modifications and variations that fall within the scope of the accompanying claims and their equivalents. Certain terminology has been selected to describe this disclosure and its constituent subsystems and components. Wherever possible, these terms have been selected based on terminology common in the art. Nevertheless, it will be understood that such terms are often subject to different interpretations. For example, what is referred to as a single component in this specification may be referred to as consisting of multiple components elsewhere, and what is referred to as including multiple components in this specification may be referred to as a single component elsewhere. Therefore, in understanding the scope of this disclosure, attention should be paid not only to the specific terms used, but also to the accompanying descriptions and context, as well as to the structure, configuration, function, and / or use of the components referenced and described, including aspects related to some figures, and the precise use of terms in the accompanying claims. Furthermore, although the following embodiments are presented in relation to exemplary applications of turbomachinery blades usable in a compressor or turbine of a gas turbine system, the art of this application is also applicable to other categories of turbomachinery, not limited to, and many other industrial components, as can be understood by an ordinary person of the art in the relevant field.

[0013] Given the nature of gas turbine operation, certain terms may be particularly useful in describing specific aspects of its function and may be advantageous in describing how they are disclosed. As is to be understood, these terms can be used when describing a gas turbine or one of its subsystems, such as a compressor, combustor, or turbine, as well as when describing or asserting components or subcomponents to be used with it. In the latter case, the terms should be understood as describing those components so that they are properly installed and / or function within the gas turbine engine or its main subsystem. These terms and their definitions are as follows, unless otherwise noted:

[0014] The terms “forward” and “rear” refer to directions related to the orientation of the gas turbine, more specifically, the relative positions of the engine’s compressor and turbine sections. Thus, as used therein, “forward” refers to the compressor end, while “rear” refers to the turbine end. It will be understood that each of these terms can be used to indicate a direction of movement or relative position along the engine’s central axis. As stated above, these terms can be used to describe one attribute of a gas turbine or its main subsystem, as well as components or subcomponents located within it. Therefore, for example, when a component such as a turbomachinery blade is described or claimed to have a “forward face,” it can be understood to refer to the face facing the forward direction defined by the orientation of the gas turbine (i.e., the compressor is designated as the forward end and the turbine as the rear end). Taking a main subsystem such as the turbine as another example (and assuming a typical gas turbine configuration as shown in Figure 1), the forward and rear directions can be defined with respect to the front end of the turbine, where the working fluid enters the turbine, and the rear end of the turbine, where the working fluid exits the turbine.

[0015] In this specification, the terms “downstream” and “upstream” are used to indicate a position within a given conduit or flow path with respect to the direction of flow moving through that conduit or flow path (hereinafter referred to as the “flow direction”). Thus, the term “downstream” refers to the direction in which the fluid flows through a given conduit, and the term “upstream” refers to the opposite direction. These terms can be interpreted as referring to the flow direction through the conduit in normal or expected operation. Considering the configuration of a gas turbine, particularly the arrangement of the compressor and turbine sections with respect to a common shaft or rotor, and the cylindrical configuration common to many combustor types, terms describing position relative to the axis can be commonly used herein. In this regard, the term “radial” will be understood to refer to movement or position perpendicular to the axis. In this connection, it may be required to describe the relative distance from the central axis. In such cases, for example, if a first component is located closer to the central axis than a second component, the first component is described as either “radially inward” or “inboard” of the second component. On the other hand, if the first component is located further away from the central axis, the first component will be described as either “radially outward” or “outboard” of the second component. As used herein, the term “axial” refers to movement or position parallel to an axis, and the term “circumferential” refers to movement or position about an axis. Unless otherwise specified or made clear from the context, these terms should be interpreted as relating to the central axis of a gas turbine compressor and / or turbine section defined by the rotor extending through each, even when describing or claiming attributes of non-integral components such as rotors or stator blades that function therein.

[0016] The terms “turbomachine blade” or “blade” refer to a rotating blade of either a compressor or a turbine, and therefore may include both compressor rotor blades and turbine rotor blades, or refer to a stationary blade of either a compressor or a turbine, and therefore may include both compressor stator blades and turbine stator blades. The term “blade” can be used in general to refer to any type of blade. Therefore, without further specification, the terms “turbomachine blade” or “blade” encompass all types of turbine engine blades, including compressor rotor blades, compressor stator blades, turbine rotor blades, turbine stator blades, etc.

[0017] Furthermore, as described below, several descriptive terms may be used regularly in this specification. The terms “First,” “Second,” and “Third” may be used interchangeably to distinguish one component from another and are not intended to imply the position or importance of any individual component.

[0018] Where used herein, the singular forms “a,” “an,” and “the” are intended to include the plural form unless the context explicitly indicates otherwise. Where used herein, the terms “comprise” and / or “comprising” identify the presence of a described feature, integer, step, operation, element, and / or component, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. “Optional” or “optional” means that the event or situation described thereafter may or may not occur, or the component or element described thereafter may or may not exist, and that the description includes both examples where the event occurs or the component exists and examples where it does not occur or does not exist.

[0019] When an element or layer is referred to as “being,” “engaging,” “connecting,” or “joining” another element or layer, it may be directly engaged, connected, or joined to the other element or layer, and there may be an intervening element or layer. In contrast, when an element is referred to as “directly,” “directly engaged,” “directly connected,” or “directly joined” to another element or layer, there may be no intervening element or layer. Other words used to describe relationships between elements should be interpreted similarly (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the related enumerated items.

[0020] As background, with specific reference to the figures, Figures 1–3 show exemplary gas turbines in which the turbomachinery components of the present disclosure may be used. Figure 1 is a schematic representation of a gas turbine 10. Generally, a gas turbine operates by extracting energy from a pressurized flow of hot gas produced by the combustion of fuel in a flow of compressed air. As illustrated in Figure 1, the gas turbine 10 may be configured to include an axial compressor 12 mechanically coupled to a downstream turbine section or turbine 14 by a common shaft or rotor, and a combustor 16 located between the compressor 12 and the turbine 14. As shown in Figure 1, the gas turbine 10 may be formed around a common central axis 18.

[0021] Figure 2 shows an illustrative multi-staged axial compressor 12 that may be used in the gas turbine 10 of Figure 1. As shown, the compressor 12 may have multiple stages, each stage including rows of compressor rotor blades 20 and rows of compressor stator blades 22. Thus, the first stage may include rows of compressor rotor blades 20 that rotate around a central shaft, followed by rows of compressor stator blades 22 that remain stationary during operation. Figure 3 shows a partial diagram of an exemplary turbine section or turbine 14 that may be used in the gas turbine 10 of Figure 1. The turbine 14 may also include multiple stages. Three exemplary stages are shown, but there may be more or fewer. Each stage may include multiple turbine nozzles (i.e., stator blades) 24 that remain stationary during operation, followed by multiple turbine buckets (i.e., rotor blades) 26 that rotate around the shaft during operation. The turbine stator blades 24 are generally spaced apart from each other in the circumferential direction and fixed to the outer casing around the axis of rotation. The turbine rotor blades 26 may be mounted on a turbine wheel or rotor disc (not shown) for rotation around a central axis. It will be understood that the turbine stator blades 24 and turbine rotor blades 26 are in the hot gas path or working fluid path through the turbine 14. The direction of flow of combustion gas or working fluid in the working fluid path is indicated by arrows.

[0022] In one example of the operation of the gas turbine 10, the airflow may be compressed by the rotation of the compressor rotor blades 20 in the axial flow compressor 12. In the combustor 16, when the compressed air is mixed with fuel and ignited, energy may be released. The resulting flow of hot gas or working fluid from the combustor 16 is then directed onto the turbine rotor blades 26, which induces the rotation of the turbine rotor blades 26 around the shaft. In this way, the energy of the working fluid flow is converted into mechanical energy of the rotating blades, which, given the connection between the rotor blades and the shaft, becomes the rotating shaft. The mechanical energy of the shaft is then used to drive the rotation of the compressor rotor blades 20 so that the required supply of compressed air is generated, and / or can be used to power a generator, for example, to produce electricity.

[0023] For background purposes, Figure 4 shows a perspective view of an exemplary part 28 having an overhang 30. For illustrative purposes, part 28 is illustrated as a flared turbomachine blade 25, more specifically as a turbine rotor blade 26. It should be noted that the teachings of this disclosure are also applicable to any part 28 having an overhang 30 other than a turbomachine blade 25, such as other hot gas path (HGP) portions of a gas turbine 10, as described herein. The teachings of this disclosure are also applicable to other industrial parts having overhangs.

[0024] The turbomachinery blade 25 may include a root 31 configured for attachment to a rotor disc. The root 31 may include, for example, a dovetail 32 configured for attachment to a corresponding dovetail slot on the outer circumference of the rotor disc. The root 31 may further include a shank 34 extending between the dovetail 32 and a platform 36. The platform 36, as shown in the figure, generally forms the junction between the root 31 and the airfoil 40, and the airfoil is the active component of the turbine bucket 26 that intercepts the flow of working fluid through the turbine 14 to guide the desired rotation. The platform 36 may define the inboard end of the airfoil 40. The platform 36 may also define a portion of the inboard boundary of the flow path of the working fluid through the turbine 14.

[0025] The airfoil 40 of a turbomachinery blade typically includes a concave pressure surface 42 and a convex suction surface 44 that is opposed to it in the circumferential or transverse direction. The pressure surface 42 and the suction surface 44 extend axially between opposing leading and trailing edges 46, 48, respectively, and radially between an inboard end that may be defined at the joint with the platform 36 and an outboard tip that may include a flared tip rail. The airfoil 40 may include a curved or contoured shape designed to promote desired aerodynamic performance.

[0026] As used herein, the turbomachine blade 25 and its components may be described in accordance with the orientation characteristics of the turbine 14. In such cases, it should be understood that the turbomachine blade 25 is assumed to be properly installed within the turbine 14. Such orientation characteristics may include radial, axial, and circumferential directions defined with respect to the central axis 18 of the turbine 14 (Figure 1). The forward and rear directions may be defined relative to the front end of the turbine 14, where the working fluid enters the turbine 14 from the combustor 16, and the rear end of the turbine 14, where the working fluid exits the turbine 14. The rotational direction may be defined relative to the expected rotational direction of the turbomachine blade 25 with respect to the central axis 18 of the turbine 14 (Figure 1) during operation.

[0027] As described above, the Disclosure provides a method for forming or repairing a part 28 having an overhang 30, for example, the flared tip of a turbomachinery blade 25. For repair purposes, the method may include removing a portion and adding a portion to the part. For the purpose of initially forming the part 28, the method may add a section to a portion of an already formed part 28. In any case, the added or formed section includes an overhang. Adding involves sequentially layering one or more material layers onto the part. When completed, the material layers approximate the dimensions of the section including the overhang. Sequential lamination can be carried out in numerous ways that form varied layers within a cross-section, including, for example, laser welding, cold metal transfer (CMT), tungsten inert gas (TIG) welding, laser sintering, direct metal laser melting (DMLM), net shape methods, near net shape methods, etc. This method and the resulting parts formed thereby can be formed by net shape methods that minimize or eliminate post-fabrication processing or finishing. This method may include machining at least one or more material layers to form sections including overhangs.

[0028] Figure 5 is an enlarged cross-sectional view of a workpiece 28 according to an embodiment of the present disclosure, having a body 60 having a first side surface 62 and an opposing second side surface 64. The body 60 may also have a longitudinal axis 75. The longitudinal axis may be any reference axis of the body 60, for example, passing through its length. In view of the airfoil 40, the longitudinal axis may be a radial axis, so that the airfoil is positioned on the gas turbine 10 (Figure 1). The overhang portion 30 extends, for example, in an overhang manner from the first side surface 62 of the body 60. The overhang portion 30 lacks vertical structural support in part. In one embodiment, the overhang portion 30 faces an opposing member 66 of the second side surface 64 of the body 60 and has more mass than the opposing member 66. In the illustrated example, component 28 includes a turbomachine blade 25, which includes a flared tip rail 70 that overhangs the suction surface 44 of the blade at, for example, the first side 62. Thus, the flared tip rail 70 is an example of an overhang portion 30 (Figure 4) of component 28. The main body 60 includes an airfoil 40, and the flared tip rail 70 faces the opposing member 66 in the form of a radially extending tip rail 134 extending from the end of the airfoil 40. The flared tip rail 70 extends circumferentially with respect to the shaft 18 (Figure 1) of the gas turbine 10. In other embodiments, the overhang portion 30 may face another overhang portion, which may or may not have a different mass, such as the flared tip rail 70, and may extend around the periphery of the airfoil 40 (see, for example, Figures 23 and 24).

[0029] The damaged overhang portion may include the overhanging flared tip rail 70, i.e., the overhanging flared tip rail lacking structural support. The portion 72 may include any structure to be removed and may include an undamaged portion or a portion with various damages, not limited to a worn surface, cracks, openings, roughness, etc. In this situation, as shown in Figure 6, the portion 72 may be removed from the part 28 to form a surface 74 on the part, for example, on the turbomachine blade 25. The portion 72 may also be defined by a surface / line 74a, where the removed portion extends deeper to the non-flared section of the suction surface 44. The portion 72 may be removed using any currently known or later developed technique, including but not limited to electrical discharge machining (EDM), mechanical cutting / grinding, laser cutting, etc. As shown in Figure 6, some remnants of the flared tip rail 70 may or may not remain, but the portion 72 is removed to form a surface 74 from which the removed portion can be reshaped. The surface 74 may be flat, curved, or have a three-dimensional shape or profile. As also shown in Figure 6, in one embodiment, the angle of the surface 74 may be a substantially horizontal plane, i.e., the vertical position of the body - longitudinal axis 75 is vertical. As described herein, the surface 74 may also be formed at a non-horizontal angle, and the part may be rotated as needed to allow the formation of a new layer. In one non-limiting example, much or half of the flared tip rail 70 is removed, for example, based on the removal of much or half of portion 72. In another non-limiting example, more than half of the flared tip rail 70 is removed, for example, based on the removal of more than half of portion 72.

[0030] Embodiments of this disclosure may also include the initial manufacture of the flared end rail 70. In this case, the starting structure, as shown in Figure 6, may be manufactured using any suitable technique for the material and structure to be constructed. Non-limiting examples may include casting and additive manufacturing. In any case, a surface 74 on which the overhang portion is to be constructed is generated.

[0031] Figure 7 is a cross-sectional view of adding section 76 to part 28, where section 76 includes a new overhang 78. The addition involves sequentially laminating a plurality of material layers 82 onto part 28, i.e., onto the surface 74. Collectively, when completed, the plurality of material layers 82 approximate the dimensions of the section containing the new overhang 78. That is, the added section approximates the dimensions of the desired new overhang 78 to be added, or the portion 72 to be replaced. As used herein, “approximate dimensions” generally indicates that the new overhang 78 can be formed by machining material removal, with little or no additional material addition. The addition of material layers 82 can be provided in many ways. For example, the material layer 82 can be formed using laser welding, laser cladding, cold metal transfer (CMT), tungsten inert gas (TIG) welding, additive manufacturing, metal sintering, direct metal laser melting (DMLM), etc. In this case, as shown in the enlarged cross-sectional view of the material layer 82 in Figure 8, sequentially laminating multiple material layers 80 onto the part 28 involves forming a series of weld beads 84 to form each layer 82. Any number of weld beads 84 can be used to form a single layer. The layers can be formed using any pattern of welding, for example, by forming a continuous spiral weld bead starting from the center or periphery, by forming individual linear weld beads side by side extending from side to side of the surface 74, or a combination thereof.The surface 74 can be positioned substantially horizontally (e.g., within ±3° from the horizontal) during sequential lamination to facilitate uniform lamination of the material, and then the portion 72 can be replaced by sequentially laminating at least one or more material layers 80 on the surface 74.

[0032] In Figure 7, only a single or multiple material layers 80 are used. Here, the second end 90 of the multiple material layers 82 is arranged in a stepped manner to approximate the dimensions of the overhang (to be formed). In one example, the first end 86 of the single or multiple material layers 82 is shown to be roughly aligned with the surface 88 of the part 28, and the second end 90 of the single or multiple material layers 82 extends in a stepped manner to be approximately the same as the dimensions of the overhang (to be formed). Here, the second end 90 progressively extends over a larger area beyond the suction surface 44 of the turbomachinery blade 25 in an overhang manner, moving upward as shown. Here, each layer 82 may have its first end 86 aligned radially or vertically. Note that the first end 86 of the single or multiple material layers 82 may not be precisely aligned as shown, and may have uneven edges (uneven multiple ends) relative to the surface 88 of the part 28. These uneven edges can be later machined to align with the surface 88 of part 28.

[0033] Figure 9 is a schematic plan view of weld beads 84 of layer 82. As shown, weld beads 84 of different layers 82A may be angled relative to weld beads 84 of other layers 82B. For example, a series of weld beads 84 of at least one first material layer 82A of multiple material layers 80 may be formed at a non-parallel angle to a series of weld beads 84 of at least one second material layer 82B of the same multiple layers 80. Any angle can be adopted to foster strength in the new section 76 (Figure 10). In addition to the direction of the weld beads, sequential lamination may be carried out in a way that controls the local temperature of the structure to prevent thermal cracking. For example, a user can jump from place to place on the build surface 74 to allow cooling in one area while working in another area, and to ensure that the new weld bead is applied in a cooled location before applying the new weld bead.

[0034] Figure 10 shows part 28 after machining multiple material layers 80 82 to form a new section 76 including a new overhang 78. If the process replaces part 72 (Figure 5), the overhang 78 may match the shape and dimensions of part 72 (Figure 5). Alternatively, it may have a different shape and dimensions to provide improved performance and / or lifespan. Machining may include any form of material removal that allows for surface mixing, resulting in the desired shape and dimensions for the new section 76. Non-limiting and non-exclusive examples of machining include milling, grinding, cutting, polishing, etc. As previously mentioned, the body 60 may include the airfoil 40 of the turbomachine blade 25. In this case, the overhang 78 includes a flared tip rail 70 extending from one of the first side 62 (not shown) and second side 64 of the airfoil 40. In Figure 10, the turbomachine blade 25 includes a flared tip rail 70 extending from the airfoil 40, and the radially-facing outer surface 138 of the overhang portion 78 is parallel to the axis 18 of the turbomachine.

[0035] In Figure 7, the surface 74 is formed to be parallel to the radially oriented outer surface 92 of the new section 76, and extends, for example, parallel to the axis 18 (Figure 1) of the gas turbine 10 (Figure 1). In other words, the surface 74 extends perpendicular to the longitudinal axis 75 of the part, or, in terms of the turbomachinery blade, perpendicular to the radial axis 75 of the body 60 of the airfoil 40. As a result, the part 28 includes at least a portion of an overhang 78 containing a plurality of material layers 82, each material layer 82 extending at an angle perpendicular to the longitudinal axis 75 of the body 60. The portion of the overhang 78 may include at most half of the overhang 78, or more than half of the overhang 78, extending from the floor surface 136 to the radially oriented outer surface of the overhang 78 (when the blade is mounted). In an alternative embodiment, as shown in Figure 25, the part 28 can be rotated so that the surface 74 is tilted from horizontal. For example, the rotation angle θ1 may be approximately 15° to approximately 60°, such that the longitudinal axis 75 of part 28 is rotated from vertical to an angle θ1. Figure 26 is a cross-sectional view of adding a new section 76 to part 28, the new section 76 including a new overhang 78. The addition involves sequentially laminating a plurality of 80 inclined material layers 82 onto part 28, i.e., onto the inclined surface 74. Collectively, when completed, the plurality of 80 material layers 82 approximate the dimensions of the new section 76 including the overhang 78 with a larger overhang angle than would be obtained with a horizontal surface construction, as shown in Figure 7. That is, the added section 76 approximates the dimensions of the desired new overhang 78 to be added, or the damaged section 72 to be replaced (Figure 5), or, if desired, the dimensions with a larger overhang angle. For example, the overhang angle θ2 may be approximately 50° to approximately 65°, or approximately 55° to approximately 60°. The overhang angle θ2 is measured between the longitudinal axis 75 of the part and a line that intersects the bottom corner (or edge) of the overhang material layer 82, as shown in Figure 26. The slanted construction reduces the perceived overhang of each layer, allowing for better acquisition of greater amounts of overhang.

[0036] As shown in Figure 11, in an alternative embodiment, removing portion 72 of part 28 may include creating a surface 94 that is not perpendicular to the longitudinal axis 75 of the body 60, i.e., the radial axis 75 of the body 60 of the airfoil 40. Rather, the surface 94 may be at an acute angle δ with respect to the longitudinal axis 75 of the body 60, i.e., the radial axis 75 of the airfoil 40. For clarity, an acute angle is between 0° and 90°. The surface 94 may also be at an acute angle α with respect to the axis 18 of the gas turbine 10 (added as a phantom line in Figure 11). Furthermore, the surface 94 will be at an angle that is neither perpendicular nor parallel to the new overhang portion 78 of the final product, i.e., the outer flat surface 96 (Figure 14) facing the target radial direction of the new flare tip rail.

[0037] As shown in Figure 13A, the surface 94 can be rotated to be substantially horizontal (±3°) before a plurality of material layers 82 are sequentially laminated thereon. Alternatively, as shown in Figure 13B, the part 28 can be rotated so that the surface 94 is positioned at an angle β other than horizontal or vertical before a plurality of material layers 82 are sequentially laminated thereon. Alternatively, the part 28 may be rotated to the position in Figure 13B after a certain number of material layers 82 have been sequentially laminated. The angle β can be any angle that allows for a desired step of a plurality of material layers 80, i.e., any angle that is not substantially horizontal as defined herein. For example, the angle β can be such that the end 98 of the layer 82 steps outward in such a way that the end can be later machined to align with the surface 88, and the end 100 of the layer 82 steps outward in such a way that it forms a new overhang 78 of the part 28. The angle β can allow for the formation of an overhang 78 that has a range that could not be formed if the surface 94 were horizontal. For example, the outward length L2 (Figure 14) of the new overhang portion 78 may be greater than the initial outward length L1 (Figure 11) of the original overhang portion 30, and the angle ε2 of the new overhang portion 78 with respect to the radial axis 75 of the main body 60 may be greater than the initial angle ε1 (Figure 11) of the original overhang portion 30 with respect to the radial axis 75 of the main body 60. The angle β can be any angle that allows sequential lamination without allowing the formation of undesirable layers, such as in the form of dripping, slumping, or breaking.

[0038] Figures 13A-B also show sequential lamination of multiple material layers 82 on a surface 94. In this case, each end 98,100 of the layer 82 may be stepped. That is, as shown in Figures 13A-B, the sequential lamination of multiple material layers 82 may include forming a first end 98 of the multiple material layers stepped from a first side of the surface 94, and forming a second end 100 of the multiple material layers 82 stepped from a second side of the surface 94. One of the first and second ends (100 as shown) approximates the dimensions of a section 76 including an overhang 78, as described herein. The end 98 may be stepped so as to align with the surface 88 of the part 28 when completed, and as previously stated, the end 100 may be stepped so as to form a new overhang 78 of the part 28, for example, a new flared tip rail of a turbomachinery blade 25. Here, as shown by the phantom lines in Figure 14, after machining, the layer 82 of the new overhang portion 78 of the finished product extends at an acute angle α with respect to the axis 18 of the gas turbine 10 (Figure 1) (roughly shown by the phantom lines), at an acute angle α with respect to the target outer surface 96 (target surface, Figure 14), and at an acute angle δ with respect to the longitudinal axis 75 of the main body 60 or part 28 (i.e., the radial axis 75 of the airfoil 40). Furthermore, the target outer surface 96, when completed, is at an angle α with respect to the surface 94 on which multiple material layers 82 and layers are built. Although the target surface 96 is shown as a plane, it should be understood that it may not be plane; for example, the surface 96 may be curved or have a three-dimensional profile.

[0039] Figure 14 shows the machining of multiple material layers 82 to form an overhang portion 78 and a target outer flat surface 138. The target outer (flat) surface 96 is at an angle α with respect to the multiple material layers 82. The turbomachinery component 28 shown in Figure 14 includes a body 60 having a first side surface 62, a second side surface 64 that may face the first side surface 62, and a longitudinal axis 75. The overhang portion 76 extends in an overhang manner from at least one of the first side surface 62 (not shown) and the second side surface 64 of the body 60. Figure 23 shows the overhang portion extending from both sides. As described in Figure 14, at least a portion of the overhang portion 78 includes multiple material layers 82, each material layer 82 extending at an acute angle δ with respect to the longitudinal axis 75 of the body 60. In one embodiment, a radially extending tip rail 134 may extend from the airfoil 40 (from the other side of the main body 60), and the radially facing outer surface 138 of the overhang portion 78 may be parallel to the shaft 18 of the turbomachine when in the operating position.

[0040] Referring to Figures 15-22, in another embodiment of the present disclosure, one or more material layers 82 can be used to form a new section 76 including a new overhang 78. Here, section 76 may be added to part 28 including the overhang 78 by sequentially laminating one or more material layers. This method may include sequentially laminating a first set of material layers onto a part extending in a first direction, and sequentially laminating a second set of material layers onto a part extending in a second direction different from the first direction, for example, two sets of layers constructed on a vertical surface formed on the part. The second set of material layers generally meet with the first set of material layers, i.e., form a new section 76. Different layers within each set of layers may be made of different materials; for example, material layers may alternate materials within a given set of layers. Additionally or alternatively, the materials within each set of layers may be the same, but two sets of layers may use different materials. Any or both of the multiple material layers 82 may be made of the same or different materials as the body 60.

[0041] As shown in Figures 6 and 15, when applied to a used part, any portion 72 of the part 28 can be removed to form a surface 74. Otherwise, the formation of the new section 76 may be from the initially formed part, as shown in Figure 6. In one embodiment, as shown in Figure 15, adding a section 76 to a part 28 including an overhang portion 78 may involve sequentially laminating a first plurality 110 material layers 82 on the part 28 extending in a first direction, for example, a direction that is generally horizontal as shown, but possibly has some angle away from the horizontal. In this example, the first plurality 110 of layers 82 can be sequentially formed horizontally on the part 28 in a way that consumes a portion 112 (Figure 6) of the flared tip rail 70. Alternatively, as shown in Figure 16, prior to the first sequential lamination, any desired material, such as a portion 112 (Figure 6) of the flared tip rail 70, may be removed to form another surface 114. That is, another portion 112 of the part 28 is removed to form another surface 114. In this case, after any necessary rotations, the layers 82 may be formed sequentially horizontally on the surface 114 on the part 28, i.e., without consuming other material. In this configuration, the sequential lamination of the first plurality 110 of material layers 82 lies on the surface 114 and forms an extension 116 of the surface 114. The ends 118 of the layers 82 are ideally aligned with the surface 74 when formed, but if not, they can be machined to align with the surface 74. In Figure 15, the sequential lamination of the first plurality 110 of material layers 82 forms an extension 116 of the surface 74. As described herein, alternative embodiments may form extensions with stepped ends (see, for example, Figures 18C and 19).

[0042] Figure 17 shows the part 28 being rotated so that the surface 74 is at a different angle, for example, substantially horizontal, and Figure 18A shows the sequential layering of the second plurality 120 of material layer 82 on the part 28 in a second different direction, for example, in a direction perpendicular to the first plurality 110 of material layer 82. In this embodiment, as described above, the sequential layering of the first plurality 110 of material layer 82 creates an extension 116 of the surface 74, and as shown in Figure 18A, the sequential layering of the second plurality 120 of material layer 82 lies on the first surface 74 and its extension 116. The second plurality 120 of material layer 82 meets the first plurality 110 of material layer 82, that is, they generally come together and mate or generally mate together.

[0043] Figures 18A–18E illustrate various embodiments in which a first plurality 110 of material layers 82 and a second plurality 120 of material layers 82 collectively approximate the dimensions of a new section 76 including a new overhang 78, resulting in them being nonplanar to one another. As described, the second plurality 120 of material layers 82 can extend in various nonplanar directions (i.e., not in the same plane) with respect to the first direction of the first plurality 110 of material layers 82. Figures 17 and 18A illustrate embodiments in which the ultimately horizontal second plurality 120 of material layers 82 extends above the vertical first plurality 110 of material layers 82, i.e., the angle γ between surfaces 74, 114 is substantially vertical (90° ± 2°). Figure 18B illustrates an alternative embodiment in which the plurality 110, 120 of material layers are positionally reversed. That is, the second plurality 120 of material layer 82 is first formed on the surface 74, providing the extension 116. Next, the part 28 is rotated so that the surface 114 and the extension 116 can be constructed, and the first plurality 110 of material layer 82 is formed. The first plurality 110 of material layer 182 terminates by extending the adjacent ends of the second plurality 120 of material layer 82 that form the extension 116.

[0044] Figure 18C shows another alternative embodiment of the part after each of the multiple sequential laminations has been repeated. In other words, fewer material layers 82 than all of the material layers 82 of the first and second multiples 110, 120 are formed on the part during the rotation of the part. Here, a number of material layers 82 less than all of the layers of the first or second multiples 110, 120, e.g., 1-4, are built on one surface 74, 114, then the part is rotated, and another number of material layers 82 less than all of the other multiples 110, 120, e.g., 1-4, are built on the opposing surface 74, 114. This approach forms a stepped or roughly stepped fit of the groups of layers 82 within each multiple 110, 120. This process may be advantageous for reducing thermal stress and addressing other mechanical problems.

[0045] Figures 18D-E show other alternative embodiments of the component in which surfaces 74 and 114 are formed in a non-planar direction and have a non-right angle γ. Here, the position of surfaces 74 or 114 in the lamination of each of the multiple 110 and 120 of material layers 82 can be any position necessary to ensure the desired bonding of the layers and to accommodate hardware welding constraints. Figure 18D shows surfaces 74 and 114 at an obtuse angle γ (90° < γ < 180°), and Figure 18E shows surfaces 74 and 114 at an angle γ greater than 180°.

[0046] Figures 19 to 21 show alternative embodiments that are substantially the same as those described in relation to Figures 15 to 18E, except that the sequential lamination of the first and second plurality 110, 120 of the material layer 82 each creates stair-stepped ends that generally meet with one another. Similar to Figures 15 and 16, the first sequential lamination can consume a portion 112 of the part, or remove a portion 112 of the part and complete the lamination on the surface to create another surface 114. In any case, prior to lamination, in the case of used part applications, any portion 72 of the part 28 can be removed to create surfaces 74, 114.

[0047] Figure 19 shows the sequential lamination of a first plurality 110 of material layers 82 to create a stair-stepped extension 122 of surface 114. Figure 20 shows any required rotation of the part, and Figure 21 shows the sequential lamination of a second plurality 120 of material layers 82 on surface 74 and the stair-stepped extension 122 of surface 74 (Figure 20). More specifically, the sequential lamination of the second plurality 120 of material layers 82 on surface 74 is carried out to form an interlocking connection by roughly fitting the material layers 82 with the stair-stepped extension 122 of surface 74 formed by the first plurality 110 of material layers 82. Here, as shown in Figure 21, the two plurality 110, 120 of material layers 82 may have mating stair-stepped ends or may have roughly mating stair-stepped ends with some voids 83 between them at some positions. That is, the ends of the first plurality 110 of material layer 82 meet the ends of the second plurality 120 of material layer 82 in a stepped manner, possibly with some voids 83 therein. The surfaces 74, 114 are shown to be perpendicular to each other in Figures 19-22, but any of the angles γ described in relation to Figures 18A-E may be adopted together with the stepped layers.

[0048] Figure 22 shows part 28 after machining multiple 110, 120 of material layer 82 to form section 76 including a new overhang 78. This process can follow any of the described processes of sequentially laminating multiple material layers. This machining process can be as described in relation to Figure 10. Although the machining is shown to be performed from the embodiment in Figure 21, it will be recognized that similar machining may be performed for embodiments in Figures 18A-E.

[0049] Figure 22 shows a turbomachinery component 28 including a body 60 having a first side portion 62 and a second side portion 64. The overhang portion 78 extends in an overhang manner from at least one of the first side portion 62 and the second side portion 64 (not shown) of the body 60. At least a portion of the overhang portion 78 extends relative to the first direction of the first plurality 110 of the material layer 82 extending in the first direction and the second plurality 120 of the material layer 82 extending in the second direction, in a non-planar direction (see angle γ) (see Figures 18A-E).

[0050] Figure 23 is an enlarged cross-sectional view of a component 28 according to another embodiment of the present disclosure, having a body 60 with a first side surface 62 and an opposing second side surface 64. Here, the overhangs 30, 230 extend overhangingly from the first side surface 62 and the second side surface 64 of the body 60, respectively. Both overhangs 30, 230 lack vertical structural support in part. In this embodiment, the overhangs 30, 230 may have the same mass and extend over the same range, or one or the other may have more mass and extend over different ranges. In the illustrated example, component 28 includes a turbomachine blade 25, including flared tip rails 70, 270 that overhang, for example, the suction surface 44 and the pressure surface 42 of the blade. However, it should be noted that the flared tip rail 70 may extend around the entire circumference of the tip of the airfoil 40. Therefore, the flare tip rail 70 is an example of the overhang portion 30,230 of part 28. The body 60 includes the airfoil 40 and the flare tip rail 70. The flare tip rail 70 extends circumferentially with respect to the shaft 18 of the gas turbine 10 (Figure 1). Figures 5-22 show the process for repairing the flare tip rail 70 on one side of the airfoil 40, but it will be readily apparent that the teachings of this disclosure can be repeated as many times as necessary and on as many construction surfaces 74,94,114,116 as necessary. Any number of portions 72 (damaged overhang portions) can be repaired or added.

[0051] Figure 24 is an enlarged cross-sectional view of a component 28 having a body 60 with a first side surface 62 and an opposing second side surface 64, according to another embodiment of the present disclosure. In Figures 5-23, the overhangs 30, 230 extend outward relative to the body 60 of the airfoil 40. In Figure 24, the overhangs 330, 430 extend inward as overhangs from the first side surface 62 and the second side surface 64 of the body 60, respectively. Both overhangs 330, 430 lack vertical structural support in part. In this embodiment, the overhangs 330, 430 may have the same mass and extend inward to the same extent, or one or the other may have more mass and extend to different extents. Although not shown, it will be recognized that one of the inwardly extending overhangs 330, 430 may be replaced with a radially extending end rail 134 as shown in Figure 5. The overhangs 330, 430 may be modified or added according to any of the embodiments described herein. It should be understood that the overhangs may extend over the pressure surface 42, the suction surface 44, and the floor surface 136, or all of these surfaces / surfaces, or any combination thereof.

[0052] Component 28 may contain metal. In one embodiment, component 28 is made from a metal such as a superalloy or metal alloy having a columnar grain structure (e.g., directional solidification (DS) blades). In one embodiment, component 28 can be made from a first metal which may contain a pure metal or alloy. As used herein, “superalloy” refers to an alloy having a number of superior physical properties compared to conventional alloys, such as high mechanical strength, high thermal creep deformation resistance, etc., such as Rene N5, Rene N500, Rene 108, CM247, Haynes alloy, Inconel, MP98T, TMS alloy, and CMSX single crystal alloy. In one embodiment, a superalloy in which the teachings of this disclosure may be particularly advantageous is a superalloy having a high gamma prime (γ') value. “Gamma prime” (γ') is the main strengthening phase in nickel-based alloys. Examples of high-gamma-prime superalloys include, but are not limited to, Rene 108, N4, N5, N500, GTD 444, MarM 247, and IN 738. The new section 76 and multiple 80, 110, 120 of the material layer 82 contain the first metal, and the turbomachine blade 25 can be made from all the same material. In an alternative embodiment, section 76 may contain a second metal different from the first metal. In one embodiment, all of the layers 82 of a particular multiple 80, 110, 120 may be made of the same material, but a different material from the rest of the part 28. That is, the part 28 contains the first metal, and the multiple 80, 110, 120 of the material layer 82 contain a second metal different from the first metal. Thus, the new section 76 may be made of a uniform material. Alternatively, the multiple layers 80, 110, and 120 of the material layer 82 may be different, and as a result, the new section 76 may have different materials therein. That is, the multiple layers 80, 110, and 120 of the material layer 82 may include at least one first material layer containing a first metal and at least one second material layer containing a second metal different from the first metal.For example, a material layer 82 of a new section 76 near surface 74 or surface 114 may be the same material as the part 28, while layers further away from surface 74 or surface 94 may be made of a different material, such as a harder material to be more wear-resistant. Alternatively, different layers may contain different materials. That is, at least one of the 80, 110, 120 of the material layer 82 may contain at least one first material layer containing a first metal, and at least one second material layer may contain a second metal different from the first metal. Figures 10, 14, and 22 show the material layers as phantom lines.

[0053] Referring to Figures 4, 10, 14, and 22, embodiments of the present disclosure also include a turbomachinery component 130 for a gas turbine 10 (Figure 1). The turbomachinery component 130 may include a turbomachinery blade 25, which includes a body 60 in the form of an airfoil 40 having a first side surface 62 in the form of a suction surface 44 and a second side surface 64 in the form of a pressure surface 42, as shown in Figures 4 and 5. The turbomachinery component 130 in the form of a turbomachinery blade 25 may also include a route 31 (Figure 4). As shown in Figures 10, 14, and 22, the turbomachinery component 130 may also include a new overhang portion 78 in the form of a flared tip rail 132 that extends overhangingly from at least one of the first side surface 62 and the second side surface 64 of the body 60, i.e., from at least one of the pressure surface 42 and the suction surface 44 (described later) of the airfoil 40. As shown in Figure 14, an overhang portion 78 in the form of a new flared tip rail 132 can face an opposing member 66 on the second side 64 of the body 60 in the form of a radially extending tip rail 134. The overhang portion 78 and the opposing member 66 extend from the floor surface 136 of the body, for example, the radially outer surface of the airfoil 40. The overhang portion 30 may have more mass than the opposing member 66. As shown in Figure 23, overhang portions 30, 230 in the form of a new flared tip rail 232 may be formed on the body 60. It is emphasized that each overhang portion 30, 230 in Figure 23 may take any form of the embodiments described herein. As shown in Figure 24, overhang portions 330, 430 in the form of a new inwardly extending flared tip rail (plural) may also be formed on the body 60. In any case, the overhangs extend from the floor surface 136, i.e., the radially outer surface of the airfoil 40. The overhangs 30, 230, 330, and 430 may have the same or different masses and may extend to the same or different extents. In any case, the overhangs 30, 230, 330, and 430 extend circumferentially with respect to the shaft 18 of the turbomachinery (Figure 1). It should also be noted that the overhangs 30, 230, 330, and 430 may take the form of a single unit-type overhang extending around the entire periphery of the airfoil 40.

[0054] As described herein, the overhang portions 30, 230, 330, and 430 in the form of a flared tip rail 132 include at least one or more material layers 82 therein. In one embodiment, the layers 82 are arranged on more than half of the overhang portion extending from the floor surface 136 to the radially facing outer surface 201, i.e., more than half of the portion 72 to be removed. As shown in Figure 14, in one embodiment, each material layer 82 may extend at an acute angle δ with respect to the radial axis 75 of the main body 60 and at an acute angle α with respect to the radially facing outer surface 138 of the overhang portion 30, i.e., the radially facing outer surface of the flared tip rail 132. In this configuration, the surface 94 on which the multiple 80 material layers 82 of the new flare tip rail 132 are formed may extend at an acute angle α to the operating position within the turbomachinery with respect to the shaft 18 (Figure 1) of the gas turbine 10 having the turbomachinery blades 26 and the radial axis 75 of the body 60. In another embodiment shown in Figure 22, the flare tip rail 132 may include a first multiple 110 of its material layers 82 extending in a first direction and a second multiple 120 of material layers 82 extending in a second direction in a non-planar direction (not 180°) with respect to the first direction of the first multiple 110 of material layers 82. The two multiple layers may be in contact (Figures 18A-B), may have interlocking stepped ends (Figure 22), or may have generally interlocking stepped ends with possibly some gaps 83 between them at some positions (Figure 21). In one embodiment, one of the two plurality 120 of the material layer 82 may be substantially parallel to the axis 18 (Figure 1) of the gas turbine 10 (Figure 1) when the turbomachinery component 130 is in its operating position within the turbomachinery (perpendicular to the radial axis 75). Furthermore, the other of the two plurality 110 of the material layer 82 may extend in a non-planar direction relative to the plurality 120 of the material layer 82. As shown in Figures 18A-C, the non-planar direction may be substantially perpendicular, i.e., 90°+ / -2°. Figures 18D-E show other non-planar directions that are not substantially perpendicular, i.e., not 90°+ / -2°.

[0055] The body 60 in the form of the airfoil 40 may contain a first metal, and at least one of the plurality of material layers 82 may contain a second metal different from the first metal. In other embodiments, the plurality of material layers 80, 110, 120 may include at least one first material layer containing the first metal and at least one second material layer containing a second metal different from the first metal. That is, different materials may be used within a given plurality of material layers. For example, the layer 82 of a new section 76 close to the surface 74 may match the material of the part 28, while the layers further from the surface 74 may be made of a different material, for example, a harder material to be more wear-resistant.

[0056] As shown in Figure 8, each material layer 82 may include a series of weld beads 84. As shown in Figure 9, the series of weld beads 84 for at least one first material layer 82A of the multiple material layers may be at a non-parallel angle to the series of weld beads 84 for at least one second material layer 82B of the multiple material layers.

[0057] Embodiments of the present disclosure provide several methods for creating material layers for adding and / or repairing overhangs such as flared tip rails of turbine rotor blades. Flared tip rails can be machined to have desired dimensions, shape, etc., after operation in order to maintain engine performance.

[0058] The aforementioned drawings illustrate some of the processes related to certain embodiments of the present disclosure. In this regard, each drawing represents a process related to an embodiment of the method described. It should also be noted that in some alternative embodiments, the actions shown in the drawings may occur outside the order shown in the drawings, or may actually be performed substantially simultaneously or in reverse order, depending on the related actions. Furthermore, those skilled in the art will recognize that additional steps describing the processes may be added.

[0059] The approximate terms used throughout this specification and the claims may be applied to modify any quantitative expression that is permissible without altering the fundamental function of the expression in question. Thus, values ​​modified by terms such as “about,” “approximately,” and “substantially” should not be limited to the specified exact value. In at least some examples, approximate language may correspond to the precision of the instrument used to measure the value. Within this specification and the claims, range limitations may be combined and / or interchangeable, and such ranges, unless the context or language indicates otherwise, are specified and include all subranges contained therein. “About” applied to a particular value within a range may indicate + / - 10% of the stated value(s), unless it applies to both endpoints and depends on the precision of the instrument used to measure the value(s).

[0060] All means or step-plus functional elements in the following claims, along with their corresponding structures, materials, actions, and equivalents, are intended to include any structures, materials, or actions for performing a function in combination with any other claimed elements specifically claimed. The descriptions in this disclosure are presented for illustrative and explanatory purposes and are not intended to be exhaustive or limiting to the disclosure in the disclosed form. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of this disclosure. The embodiments have been selected and described to best illustrate the principles and practical applications of this disclosure and to enable others skilled in the art to understand the disclosure in terms of various embodiments with various modifications to suit a particular intended use. [Explanation of symbols]

[0061] 10: Gas turbine 12: Compressor 14: Turbine 16: Combustor 18: Central axis 20: Compressor rotor blade 22: Compressor stator blade 24: Turbine nozzle 25: Flare tip turbomachine blade 26: Turbine bucket 28: Part 30: Overhang 31: Root 32: Dovetail 34: Shank 36: Platform 40: Airfoil 42: Pressure surface 44: Suction surface 46: Leading edge 48: Trailing edge 60: Body 62: First side surface 64: Second side surface 66: Opposing member 70: Flare tip rail 72: Part 74: Surface 75: Longitudinal axis 76: Section 78: New overhang 80: Multiple material layers 82: Material layer 83: Void 92: Radially oriented outer surface 94: Surface not perpendicular to the radial axis 96: Outer flat surface facing the target radial direction 98: First end 100: Second end 110: First multiple material layers 114: Surface 116: Extension 120: Second multiple material layers 122: Stepped extension 130: Turbomachine component 132: Flare end rail 134: End rail 136: Floor surface 138: Outer surface facing radial direction 230: Overhang

Claims

1. A main body (60) having a first side (62) and a second side (64), An overhang portion (78) extends in an overhanging manner from at least one of the first side surface (62) and the second side surface (64) of the main body (60) such that it lacks structural support in a part thereof. A turbomachinery component (28) comprising, At least a portion of the overhang portion (78) includes a plurality of first material layers (110) extending in a first direction and a plurality of second material layers (120) extending in a second direction in a non-planar direction with respect to the first direction of the plurality of first material layers (110). A turbomachinery component (28) having a main body (60) including an airfoil (40) of a turbomachinery blade (25), and an overhang portion (78) including a flared tip rail (132) extending from the end of the airfoil (40).

2. The turbomachinery component (28) according to claim 1, wherein the main body (60) comprises a first metal, and at least one of the first and second plurality of material layers (110, 120) comprises a second metal different from the first metal.

3. A turbomachinery component (28) according to claim 1, wherein in each of the first and second plurality of material layers (110, 120), at least one first material layer (82) contains a first metal and at least one second material layer (82) contains a second metal different from the first metal.

4. The turbomachinery component (28) according to claim 1, wherein each of the first and second plurality of material layers (110, 120) includes a series of weld beads (84).

5. A turbomachinery component (28) according to claim 4, wherein a series of weld beads (84) for at least one first material layer (82) of the first and second plurality of material layers (110, 120) are at a non-parallel angle to a series of weld beads (84) for at least one second material layer (82) of the first and second plurality of material layers (110, 120).

6. The turbomachinery component (28) according to claim 1, further comprising a radially extending end rail (134) extending from the end of the airfoil (40).

7. The turbomachinery component (28) according to claim 1, wherein the material layers (82) of the first and second plurality of material layers (110, 120) extend over a gradually larger area relative to the preceding material layer (82) such that the ends of the first plurality of material layers (110) meet the ends of the second plurality of material layers (120) in a stepped manner, forming a stepped end into which the first and second plurality of material layers (110, 120) fit together.

8. A gas turbine comprising a turbomachinery component (28) according to any one of claims 1 to 7.

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